Floor construction and method of making the same



June 1965 K. F. GLASER ETAL 3,187,853

FLOOR CONSTRUCTIGZ! AND METHOD OF MAKING THE SAME Filed July 6. 1960 4Sheets-Sheet 1 P- N r- 7 L. x N

00 g m v i i INVENTORS KURT F. GLASER WILLIAM J. CRABBS ZZZM JLW THEIRATTORNEYS June 1965 K. F. GLASER ETAL 3,187,853

FLOOR CONSTRUCTICEI AND METHOD OF MAKING THE SAME Filed July 6, 1960 4Sheets-Sheet 2 FIG. 4 I In] I' 2 FIG. 5 H6 6 I l 2|o I I 7 I I I I ITII1 I A I sen 58 INVENTORS KURT F. GLASER WILLIAM J. CRABBS g \1 LiaYglzam/iw THEIR ATTORNEYS June 8, 1965 K. F. GLASER ETAL 3,

FLOOR CONSTRUCTION AND METHOD OF MAKING THE SAME Filed July 6, 1960 4Sheets-Sheet 3 [I'll V FIG. 7

INVENTORS KU F. GLASER WILLI J. CRABBS THEIR ATTORNEYS June 1965 K. F.GLASER ETAL 3,187,353

FLOOR CONSTRUCTIGE AND METHOD OF MAKING THE SAME Filed July 6, 1960 4Sheets-Sheet 4 FIG. 9

INVENTORS KURT F. GLASER WILLIAM J. CRABBS avg/W $24M THEIR ATTORNEYSUnited States Patent 3,187,853 FLOOR CONSTRUCTION AND METHOD OF MAKINGTIE SAME Kurt F. Glaser and William J. Crabbs, Chesterfield County, Va.,assignors to Reynolds Metals Company, Richmond, Va., a corporation ofDelaware Filed July 6, 196i Ser. No. 41,134 2 Claims. (Cl. 189-34) Thisinvention relates to an improved floor construction and to the method ofmaking the same or thelike. More particularly, this invention relates toa metal floor construction for vehicles and the like and having meansfor readily arresting movements of loads placed thereon, and to themethod of making such floor constructions and arresting such movements.

The floor constructions of this invention each generally comprises aplurality of elongated extruded metal floor elements or planks arrangedin side by side coplanar relation to form a floor section that issecured to suitable support means of a sub-floor structure to form aload supporting, floor construction that can more than adequatelywithstand the normal rugged use thereof.

Each floor element has a pair of opposed concave and convex sidewalls,one of which is provided with an outwardly directed spacing flange orabutment extending throughout the entire length thereof whereby adjacentsidewalls of adjacent floor elements are automatically spaced by thespacing flange to provide a predetermined sinuous nailing space or pathbetween adjacent sidewalls of adjacent floor elements.

To arrest movement of a load placed on the top surfaces of the floorelements, it is merely necessary to place suitable arresting members onthe floor elements and in abutting relation with the load wherebysuitable fastening members, such .as nails or the like, can be driventhrough the arresting members and wedged into the sinuous spaces betweenadjacent side walls of adjacent floor elements to hold the arrestingmembers in place. If desired, the fastening members can rupture thespacing flanges of the floor elements .to more positively hold thefastening members in place.

One of the features of this invention is to produce, by simplewell-known extrusion methods, metal floor elements that are strong,durable, resistant to corrosion and can be readily and rapidly assembledinto the desired pattern for forming the floor constructions of thisinvention.

Further, another feature of this invention is to provide suitablestructural members secured to the floor elements in a manner whereby theassembled floor elements can be readily attached to a sub-floor strutureor the like to form a floor construction of this invention.

Accordingly, it is an object of this invention to provide a floorconstruction having each and/or every novel feature set forth above orhereinafter shown or described.

Another object of this invention is to provide an improved method formaking such floor constructions or the like. i

Further objects of this invention are to provide an improved means andan improved method for arresting movements of loads placed on such floorconstructions.

ther objects, uses and advantages of this invention are apparent from areading of this description which proceeds with reference to theaccompanying drawings forming a part thereof and wherein:

FIGURE 1 is a partially broken away, fragmentary plan view of oneembodiment of the floor construction of this invention.

FIGURE 2 is a cross-sectional view of the floor construction illustratedin FIGURE 1 and is taken on line 2-2 thereof.

Patented June 8, 1965 FIGURE 3 is an enlarged, fragmentarycross-sectional view taken on line 3-3 of FIGURE 1 and illustrates theend structure of the floor construction.

FIGURE 4 is an enlarged, fragmentary cross-sectional view taken on line4-4 of FIGURE 1 and illustrates the method of securing the floorelements to the support members of the sub-floor structure.

FIGURE 5 is an enlarged, fragmentary cross-sectional view illustratingthe method of securing the ends of the floor elements to the side railsof the sub-floor structure illustrated in FIGURE 1 and is taken on line55 thereof.

FIGURE 6 is a view similar to FIGURE 5 and illustrates anotherembodiment of this invention.

FIGURE 7 is an enlarged, fragmentary cross-sectional view taken on line7-7 of FIGURE 1 and illustrates the method of nailing an arrestingmember to the floor construction.

FIGURE 8 is a perspective view illustrating the various floor sectionsof this invention.

FIGURE 9 is an enlarged, perspective and schematic view illustrating themethod of making the floor elements of this invention.

FIGURES 10-13 are respectively schematic views illustrating the varioussteps in the method of making the floor construction illustrated inFIGURE 1.

While the floor constructions of this invention are hereinafter referredto as being particularly adaptable for vehicles, such as railroadrolling stock, truck beds and the like, it is to be understood that suchfloor constructions have a wide variety of uses and it is contemplatedthat the scope of the appended claims includes such other uses and thelike.

Referring to FIGURE 1, the floor construction of this invention isgenerally indicated by the reference numeral 24) and comprises aplurality of elongated metal fioor elements or planks 21 securedtogether at their opposed ends 22 and 23 by metal channel-like endmembers 24 and secured to transversely disposed metal strip-like members25, the channel-like end members 24 and strip-like members 25 beingrespectively secured to end rails 26 and support members 27 of asub-floor structure 28 in a manner hereinafter described.

The floor elements 21 and members 24 and 25 may be formed of any desiredmetal, combinations of metals, or combination of materials. However, inthe embodiment illustrated in the drawings the floor elements or planks21 and members 24 and 25 are formed of aluminum or an aluminum alloy,such as 6061-T6 alumin alloy.

The sub-floor structure 28 may also be formed of any suitable materialor combination thereof, and in the embodiment illustrated in thedrawings, the side rails 26 and support members 27 are formed of steelwhile other parts thereof, later to be described, are formed of wood orthe like.

When the floor elements 21 are formed of aluminum containing materialand the support members 27 of the sub-floor are formed of steel, it isd-iflicult to effect a good weld therebetween. Therefore, the aluminumcontaining strip-like members 25 are welded to the floor elements 21 andthen secured to the support members 27 in a manner hereinafterdescribed. Further, the various alu- 3 together by opposed side surfacemeans 33 and 3d, the bottom surface means 32 including threehorizontally disposed foot sections 35, 36 and 37.

The foot sections 35 and 37 are respectively interconnected to the topsurface means or Wall 31 of the extrusion 29 by the structural sidesurface means or Walls 33 and 34 While the central foot section 36 isinterconnected to the top Wall 31 by a vertically disposed web-likestructural Wall 38.

In order to assist in preventing transverse movement of a load placed onthe floor elements 21, the top Wall 31 of the extrusion 29 is providedwith a plurality of spaced, parallel and outwardly directed ribs 39throughout the entire length thereof, the purpose of the ribs 39 beingmore fully explained hereinafter.

The side Wall 33 is convex While the side Wall 34 is concave, the sideWalls 33 and 34 being complementary to each other for a purposehereinafter set forth. 7

An outwardly directed spacing flange 4t) is formed on the .side wall 33throughout the entire length thereof, the flange 46 preferably beinglocated slightly above the top surface of the foot section 35 but may beformed anywhere along the side Wall 33.

While the spacing flange 46 is illustrated as being formed on the sidewall 33 of the extrusion 29, it is to be understood that the same may beformed on the side Wall 34, if desired.

After the extrusion 29 has been formed in the manner illustrated inFIGURES 9 and 10, the extrusion is cut in any suitable manner to form aplurality of floor elements 21, FIGURE 11, of desired lengths. Forexample, the floor elements may be approximately 7.8 inches Wide, 1.75inches in height and 9 feet long.

When forming a large floor construction, such as the floor construction2%? for a railroad freight car, it may be desirable to assemble thefloor elements 2.1 into a plurality of floor sections 41, 4-2 and t3,FIGURE 8, whereby the floor sections il-d3 can be individually securedto the sub-floor 28 in a manner hereinafter described. However, it is tobe understood that one large floor section may be formed, if desired.

The floor section M is utilized for forming part of the left terminalend of the floor construction 2%) While the floor section 43 is utilizedfor forming part of the right terminal end thereof. A plurality of floorsections 42 are utilized to floor the remaining central portion of thesub-floor'28, and, in the embodiment illustrated in the drawings, eightfloor sections 45 2 and a pair of floor sections 41 and 43 are requiredto form the floorconstruction 29.

' Each floor section 42 is formed by arranging eight or any desirednumber of floor elements 21 in a side by side coplanar relationship,FIGURE 12, with the side walls 33 of each floor element 21 beingdisposed adjacent to the side wall 34 of an adjacent floor element 2-1and with the spacing flange til thereof in abutting relation with the 7adjacent side wall 34. In this manner, the spacing flanges ti) on thefloor elementsll automatically predetermine the spacing between adjacentfloor elements 21.

Since the adjacent side walls 33 and 3410f adiacent floor elements 211are complementary to each other, the spacing therebetween provides auniform sinuous path between the adjacent floor elements to receivefastening members as will be described hereinafter.

Thereafter, either the end members 24 or the strip-li members 25 aresecured to the assembled fioor elements 21. For the purpose ofillustration only, the end members 24 are hereinafter described as beingassembled to the floor elements 21 before the members 25.

a As illustrated in FIGURE 5, the end members 24 each comprises anelongated channel-like metal device formed by extrusion methods or thelike having a bight portion 44- defined by two spaced parallel flanges45 and 46 extending from the terminal ends of a straight portion 47thereof. The bight portions 44 of the end members 24 are so constructedand arranged that the same snugly A receive the respective ends 22 or 23of the floor elcs ments 21.

Thereafter, the end members Mare secured to the floor elements 21 in anydesired manner, such as by welding at 48 and d9.

Subsequently, a plurality of the extruded or cut striplike metal members25 are secured to the foot sections 3537 of the bottom surf-ace means 32of the floor elements 2]. by welding or the like, the strip-likeelements be ing disposed transversely relative to the floor elements 21and being spaced in a manner to cooperate with the support members 27 ofthe sub-floor 28 in a manner hereinafter described.

The floor sections 4d and 43 are formed in the same manner as the floorsections 42 except that a smaller number of floor elements 21 may beused and the floor elements 21a and 21b of the respective section 41 and43 respectively have the side walls 33 and 34 and their associated footsections 35 and 37 removed therefrom. For example, see FIGURE 3, whereinthe floor element 21a of the floor section 41 has the side Wall .33 andfoot section 35 removed therefrom to accommodate a support member 59 ofthe sub-floor 28. While it is not illustrated, it is to be understoodthat the side wall 34 and foot section 37 of the floor element 211') ofthe floor section 4-3 are removed to accommodate a support membersimilar to the support member 549 of FIGURE 3.

Also, it is to be understood that the floor elements 21a and 21b may beformed from separate extrusions other the extrusion that forms the floorelements 21 Whereby it is not necessary to remove any portions of theelements 21a and 21b.

The end members 24 secured to the floor elements 21 of the floorsections ill and 43 may have portions of the lower flanges 46 thereofcut away at the free ends of the respective floor elements 21a and 21bto prevent interference with the support members 5%. Similarly, thestrip-like members 25 may have their ends cut off adjacent the centralfoot sections as of the floor elements Zita and 21b to avoidinterference with the support members 56.

After the desired number of floor sections 4 1 i? have been fabricatedin the above manner, the same are adapted to be secured to the sub-floor28 or any other suitable structure.

Thus, the floor sections il-43 can be fabricated in one location andshipped or stored in their assembled condition until the same are neededto form a desired floor construction.

The sub-floor 2.8 as illustrated in FIGURES l and 2 comprises apluralityof spaced pairs of laterally disposed frame members 51 interconnected attheir inner ends to I an inverted U-shaped longitudinally disposedcentral beam or support 52 at their outer ends and to longitudinallydisposed side rails 53 carrying the side rails 26 previously described.i

The support members 27 are secured to the laterally disposed supports 51and are disposed transverse thereto. The support members 27 areillustrated as being Z-shaped beams, but it is lto'be understood thatthe same may have any desired configuration, such as l-shaped or thelike.

When it is desired to secure the floor sections il-43 to the sub-floor28, the sections 4143 are placed in the proper positions on the sub-loor28, FIGURE 13, with the strip-like members 25 disposed on the supportmembers 237 and the end members -24 disposed on the side rails 26adjacent wooden supports or frame members $4, FIG- URES 2 and 5. 7Thereafter, the strip-like members 25 are secured to the support members27 of the sub-floor 2% in any suitable manner, and, in the embodimentillustrated in the drawings, the strip-lilre members 25 are bolted tothe support members 27 by a plurality of bolts 55, FIGURE 4.

The channel-like end members 24 are also bolted to the side rails 2:; bya plurality of bolts 56, FIGURE 5, or secured thereto in any suitablemanner.

sections 35-37, to further provide means for 1 Thus, after the floorsections 41-43 have been fabricated, it is a simple and easy operationto secure the floor sections 41-43 to the sub-floor 28 to complete thefloor construction 20. Further, to replace-damaged or worn out sections41, 42 or 43, it is merely necessary to unfasten the bolts 55 and 56 andlift out the unfastened section to permit a new floor section to bemounted in place and fastened thereto by the simple fastening means 55and 56.

It should be noted that automatic'spacing is provided between adjacentfloor elements 21 of adjacent floor sections 41-43 because of thespacing flanges 40 projecting from the left hand floor elements 21 ofeach section 42 and 43.

The spacing between the floor elements 21 is filled with 'a suitablemastic substance, such as plastic cement 57,

, between adjacent floor elements when being filled.

If desired, the plastic cement 57 can be-added to the floor sections41-43 before the same have been assembled to "the sub-floor 28,- and,thereafter, the spacing between adjacent sections 41-43 can be filledwith the substance 57 after the floor sections 41-43 have been assembledto Obviously, the spacing between adjacent floor elements .21 can becontrolled by varyingthe side of the spacing flanges 40 whereby varioussized nails or fastening members 62 may be utilized. For example, it hasbeen found that when the spacing flange 40 is approximately 0.233 inchlong, twenty-penny nails are firmly held in the space between adjacentfloor elements 21 by the bending action of such sinuous space whilethirty-penny nails, which are slightly larger, score the side walls 33and 34 of adjacent floor elements 21. However, such scoring does notproduce an adverse effect, and, therefore, twenty or thirty-penny nailscan be adequately utilized when the spacing flanges 40 are of the above.size.

- While the embodiment illustrated in FIGURE 1 discloses arrestingblocks 61 in addition to arresting blocks 60, it is to be understoodthat the blocks 61 may be eliminated as the load 59 normally tends toshift longitudinally on the vehicle when 'moving to right or to the leftand not laterally thereof. Further, the smaller blocks 61 may beutilized in place ofthe larger blocks 60, as desired.

Therefore, it can be seen that there has been provided an improved floorconstruction that is easy to manufacture and assemble, strong, durable,and readily permits nailing of load arresting members thereon. Further,by

forming the spacing flanges throughout the entire length the sub-floor28. However, the cement 57 can be added in all of the spacings after thesections 41-43 have been assembled to the sub-floor 28.

Since the sub-floor structures of vehicles vary with differentmanufacturers of the same, it is to be understood that the floorsections 41-43 of this invention can be modified to accommodate suchvariations in sub-floor structures. For example, see FIGURE 6 whereinthe end members 24a have depending flanges 58 which positively locatethe end members 24a in abutting relation with the side rails 26a of thesub-floor. Also, the wooden supports 54 of FIGURE 5 have been eliminatedin the embodiment illustrated in FIGURE 6.

Further, when the floor elements 21 and support members 27 of thesub-floor 28 are formed from materials that are readily weldabletogether, the strip-like members 25 may be eliminated and the floorelements 21 welded directly to the sub-floor structure. Also, when thestrip-like elements 25 are utilized, the channel-like end members 24 maybe used in combination therewith or be eliminated as desired.

After the floor construction 20 has been formed in the above manner,loads may be placed thereon, such as load 59, FIGURE 1, and the ribs 39of the floor elements 21 tend to prevent movement thereof relative tothe floor construction 20.

. To further arrest movement of the load relative to the floorconstruction 20, it is merely necessary to place suitable load arrestingmembers on the floor construction 20 and in abutting relation with theload 59, the arresting members comprising elongated wooden blocks 60 orsmall blocks 61 formed of two by four wood stock or the like.

The arresting members 60 or 61 are secured to the floor construction 20by driving suitable nails 62, FIG- URE 7, through the blocks 60 or 61into the spacing betweens adjacent side walls 33 and 34 of adjacentfloor elements 21 whereby the nails 62 are deformed into the sinuouspath between the elements 21 to securely hold the nails 62 in place.Preferably, but not necesof the floor elements in a simple manufacturingoperation, such flanges provide automatic predetermined spacing betweenthe floor elements, prevent loss of space filling material, and assistin holding the fastening members in place. e

While the embodiment'and form of the invention now preferred has beendisclosed in accordance with the requirements of the statute, otherforms may be used, all coming within the scope of the claims whichfollow.

What is claimed is:

1. In combination, a plurality of elongated floor elements securedtogether in side by side coplanar relation, each floor element havingtop surface means and bottom surface means interconnected together byopposed side surface means, one of said side surface means having anintegral outwardly directed spacing flange extending between the opposedends thereof and having a free end extendinglaterally and engaging theother side surface means of an adjacent floor element to space adjacentside surfaces of adjacent floor elements, a load arresting memberdisposed on a portion of said top surface means, and a fastening memberdisposed in said arresting member and extending into said space betweentwo of said floor elements, said fastening member rupturing said spacingflange on one of said two floor elements.

2. A combination as set forth in claim 1 wherein said space between saidtwo floor elements defines a sinuous path for receiving said fasteningmember.

References Cited by the Examiner UNITED STATES PATENTS HARRISON R.MOSELEY, Primary Examiner. JQSEPH REZNEK, Examiner.

Seim 189-34-

1. IN COMBINATION, A PLURALITY FO ELONGATED FLOOR ELEMENTS SECURED TOGETHER IN SIDE BY SIDE COPLANAR RELATION, EACH FLOOR ELEMENT HAVING TOP SURFACE MEANS AND BOTTOM SURFACE MEANS INTERCONNECTED TOGETHER BY OPPOSED SIDE SURFACE MEANS, ONE OF SAID SIDE SURFACE MEANS HAVING AN INTEGRAL OUTWARDLY DIRECTED SPACING FLANGE EXTENDING BETWEEN THE OPPOSED ENDS THEREOF AND HAVING A FREE END EXTENDING LATERALLY AND ENGAGING THE OTHER SIDE SURFACE MEANS OF AN ADJACENT FLOOR ELEMENT, A LOAD ARRESTING SIDE SURFACES OF ADJACENT FLOOR ELEMENTS, A LOAD ARRESTING MEMBER DISPOSED ON A PORTION OF SAID TOP SURFACE MEANS, AND A FASTENING MEMBER DISPOSED IN SAID ARRESTING MEMBER AND EXTENDING INTO SAID SPACE BETWEEN TWO OF SAID FLOOR ELEMENTS, SAID FASTENING MEMBER RUPTURING SAID SPACING FLANGE ON ONE OF SAID TWO FLOOR ELEMENTS. 